Locking articulation mechanism

ABSTRACT

A surgical device including a handle assembly, an elongated body extending from the handle assembly, and an articulation mechanism connected to the handle assembly and configured to selectively articulate and lock an articulable tool assembly in one or more positions is provided. The articulation mechanism includes a main shaft member mounted for rotation and connected to an articulation linkage, a locking member configured to be received about the shaft portion of the main shaft member, the locking member defining a plurality of notches, an articulation handle fixedly secured to shaft portion of the main shaft member and configured for rotation relative to the locking member, and a lug member operatively mounted on the articulation handle and including a locking tab configured to be selectively received within a notch of the plurality of notches formed in the locking member.

BACKGROUND

1. Technical Field

The present disclosure relates to surgical instruments having one ormore articulation portions. More particularly, the present disclosurerelates to a mechanism for locking the articulating portion of thesurgical instrument in a plurality positions.

2. Background of Related Art

Various instruments have been modified for use in closed procedures,i.e., laparoscopic, arthroscopic, endoscopic. Such instruments typicallyinclude an elongated body portion configure to extend through an openingin a patient, i.e., through an access port, and/or thorough a naturalorifice, e.g., anus, mouth.

Many of these instruments adapted for use in closed procedures includean articulable tool assembly mounted on a distal end of an elongatedbody portion. The tool assembly is controlled remotely from the handleassembly mounted on the proximal end of the elongated body portion. Anarticulation mechanism mounted on the handle assembly allows for theremote articulation of the tool assembly relative to the elongated bodyportion. Generally, the articulation mechanism includes a lever mountedon the handle assembly that, when turned, advances or retracts anarticulation linkage. The articulation link extends through theelongated body portion and is operably connected to the tool assembly.Longitudinal advancement and retraction of the articulation linkagecauses articulation of the tool assembly. The tool assembly ismaintained in a desired position solely through the friction between thelever and the handle. In this manner, if a clinician were toaccidentally contact the tool assembly with a structure within the bodywith sufficient force, the force could cause the tool assembly to bedeflected from the desired position.

Therefore, it would be beneficial to have an articulation mechanismconfigured to selectively lock the tool assembly in one or moreposition.

SUMMARY

Accordingly, a surgical instrument including a locking articulationmechanism is provided.

DESCRIPTION OF THE DRAWINGS

Embodiments of a locking articulation mechanism are disclosed hereinwith reference to the drawings, wherein:

FIG. 1 is a perspective view of a surgical device including a lockingarticulation mechanism according to an embodiment of the presentdisclosure;

FIG. 2 is an enlarged perspective view of portion 2 of FIG. 1;

FIG. 3 is an exploded perspective view of the locking articulationmechanism of FIG. 1;

FIG. 4 is a cut-away side view of the locking articulation mechanism ofFIG. 1;

FIG. 5 is cross-sectional view of the locking articulation mechanism ofFIG. 1;

FIG. 6 is a cross-sectional view of the locking articulation mechanismof FIG. 1, taken along line 6-6 of FIG. 5;

FIG. 7 is a top view of the locking cover and lug member of the lockingarticulation mechanism of FIG. 1, in an initial, locked position;

FIG. 8 is a top view of the locking cover and lug member of the lockingarticulation mechanism of FIG. 1, in a second, unlocked position;

FIG. 9 is a top view of the locking articulation mechanism of FIG. 1with the lug member in an initial or locked position and thearticulation lever in a non-articulated position;

FIG. 10 is a top view of the locking articulation mechanism of FIG. 1with the lug member in a second or unlocked position and thearticulation lever in an articulated position;

FIG. 11 is a top view of the locking articulation mechanism of FIG. 1with the lug member in the initial or locked position and thearticulation lever in a further articulated position; and

FIG. 12 is an enlarged perspective view of an articulation leveraccording to another embodiment of the present disclosure.

DETAILED DESCRIPTION

Embodiments of the presently disclosed locking articulation mechanismwill now be described in detail with reference to the drawings whereinlike numerals designate identical or corresponding elements in each ofthe several views. As is common in the art, the term “proximal” refersto that part or component closer to the user or operator, i.e.clinician, while the term “distal” refers to that part or componentfurther away from the user. Although the articulation mechanism of thepresent disclosure will be described as it relates to a surgical devicehaving a selectively attachable loading unit having a tool assembly, thepresently disclosed articulation mechanism may be modified for use withother articulating surgical devices. For example, the tool assembly mayhave a removable and replaceable cartridge assembly.

FIGS. 1-11 illustrate an embodiment of a locking articulation mechanismaccording to the present disclosure, shown generally as lockingarticulation mechanism 100. As shown in FIG. 1, and as will be discussedhereinbelow, locking articulation mechanism 100 is incorporated into asurgical device 10. Surgical device 10 includes a handle assembly 20 andan elongated body 30 extending from handle assembly 20. A distal end ofelongated body 30 is configured to receive a loading unit that includesan articulating tool assembly (not shown). Surgical device 10 may beconfigured for use in open or closed, i.e., laparoscopic, endoscopic,procedures. The structure and function of surgical device 10 will onlybe described herein to the extent necessary to fully disclose lockingarticulation mechanism 100. For a more detailed description of thestructure and function of a surgical stapler, please refer to commonlyowed U.S. Pat. No. 5,865,361 to Milliman et al., the content of which ishereby incorporated herein by reference, in its entirety.

With reference now to FIGS. 1-3, articulation mechanism 100 includes anarticulation housing 102 having upper and lower housing or knob halves104, 106. Upper and lower housing halves 104, 106 are configured to bereceived about a distal end of handle assembly 20 and a proximal end ofelongated body 30. Articulation housing 102 is configured to facilitaterotation of elongated body 30 about a longitudinal axis “x”. Each ofupper and lower housing halves 104, 106 include knurled proximal ends104 a, 106 a configured for operable engagement by the user. Upperhousing half 104 defines an opening 105 (FIG. 5) extending therethrough.Upper housing half 104 further defines a plurality of slots (not shown)extending radially outwardly of opening 105. As will be discussed infurther detail below, the number of slots formed in upper housing half104 corresponds in number and location with tabs 124 of retainer 120 andflanges 134 of locking member 130 (FIG. 4).

With reference now to FIGS. 3 and 4, articulation mechanism 100 furtherincludes a main shaft member 110, a retainer 120, a locking member orcover 130, an articulation lever 140, a lug member 150 and a channelyoke 160. As discussed above, the term “proximal” refers to that part orcomponent closer to the user or operator. Since the user will engage lugmember 150 and articulation handle 140 of articulation mechanism 100,reference will be made to articulation handle 140 being at a proximalend of locking articulation mechanism 100, while channel yoke 160 islocated at a distal end thereof. The articulation handle 140 may beconfigured as a lever, knob, or the like.

Still referring to FIGS. 3 and 4, main shaft member 110 includes a baseportion 112 and a shaft portion 114 extending from base portion 112.Base portion 112 is configured to be rotatably received within opening105 (FIG. 5) of upper housing half 104. Base portion 112 includes aradially outward extending slot 113 a. In one embodiment, slot 113 a isconfigured to selectively receive a protrusion feature (not shown) of asensor cap 111 shown in FIG. 5, extending, at least partially withinarticulation housing 102. Base portion 112 further includes an opening112 b formed therethrough. As will be discussed in further detail below,opening 113 b is configured to engage a portion 165 a of a cam pin 165(FIG. 3). Shaft portion 114 of main shaft member 110 includes a pair oflongitudinally extending notches 115 a, 115 b. Notches 115 a, 115 b formopposed substantially U-shaped recesses that extend substantially thelength of shaft portion 114. Although shown having the same U-shapeprofile, recesses 115 a, 115 b may include alternatively shaped profilesand/or the profiles may differ in shape. Shaft portion 114 furtherincludes an opening 117 extending radially through a proximal end 114 athereof. As will be discussed in further detail below, opening 117 isconfigured to receive a pin 145 (FIG. 3) to secure articulation lever140 with main shaft 110.

With continued reference to FIGS. 3 and 4, retainer 120 forms asubstantially planar member 122 including a plurality of radiallyoutwardly extending tabs 124. As shown, planar member 122 includes four(4) tabs 124 corresponding in number and placement to slots (not shown)formed about opening 105 in upper housing half 104. The number andspacing of tabs 124 may vary to depending on the number and placement ofthe slots formed in upper housing half 104. It is contemplated thatplanar member 122 may include fewer tabs 124 than there are slots inupper housing half 102. Retainer 120 defines an opening 123 extendingthrough the center of planar member 122. Opening 123 is sized toreceived about shaft portion 114 of main shaft member 110. Withreference now to FIGS. 3-5, 7 and 8 locking member or cover 130 definesa substantially annular member 132 having a proximal surface 132 a and adistal surface 132 b. Proximal surface 132 a is configured to engage andstabilize articulation lever 140. As shown, proximal surface 132 a isinclined, however, other configurations, e.g., stepped, may be employedfor stabilizing articulation lever 140. A plurality of feet 134 extenddistally from annular member 132 for securing locking member 130 toupper housing half 104 of articulation housing 102. As shown, lockingmember 130 includes four (4) feet 134 evenly spaced about annular member132. Locking member 130 may include more or less than four locking feet134 that may or may not be evenly spaced about annular member 132.

With reference still to FIGS. 3-5, 7 and 8, annular member 132 oflocking member 130 defines a longitudinal bore 131 extendingtherethrough and a semi-circular cut-out 133 radially spaced fromlongitudinal bore 131. As will be discussed in further detail below,cut-out 133 is configured to slidingly receive a flange 146 (FIG. 5) ofarticulation lever 140. Annular member 132 of locking member 130 furtherincludes a plurality of notches 135 extending radially outward aboutsemi-circular cut-out 133. Notches 135 are configured to receive alocking tab 156 of lug member 150. As will be discussed in furtherdetail below, notches 135 are configured such that articulationmechanism 100 may selectively secure a tool assembly in predeterminedarticulated or non-articulated positions. Notches 135 may be evenlyspaced, as shown, to permit incremental articulation of the toolassembly. Alternatively, notches 135 may include any other predeterminedspacing, thereby resulting in predetermined incremental articulation ofthe tool assembly. As shown, a central notch 135 a is formed in lockingmember 130 and is positioned such that when locking tab 156 of lugmember 150 is received therein, articulation lever 140 is aligned withlongitudinal axis “x”, thereby securing the articulable tool assembly onsurgical device 10 (FIG. 1) in a non-articulated position.

With reference now to FIGS. 3-6, articulation handle 140 includes asubstantially circular base 142 and an elongated portion 144.Articulation handle 140 defines a recess 141 configured to receive anend 114 a of shaft portion 114 of main shaft 110 and be received aboutannular body 132 of locking member 130. Articulation handle 140 furtherincludes an opening 143 extending radially therethrough for receivingpin 145. Pin 145 is configured to fixedly secure articulation handle 140to shaft portion 114 of main shaft member 110. The retainer holds themain shaft and the lever 140 down. For example, the locking member 130flanges 134 can be used to hold down retainer flanges 124 which holddown main shaft and lever assembly.

Articulation handle 140 further includes a flange portion 146 (FIG. 5)extending distally therefrom. Flange portion 146 is configured to beslideably received within semi-circular cutout 133 of locking member130. A first end 144 a of elongated portion 144 is configured forengagement by a user. A second end 144 b of elongated portion 144 isconfigured for operable engagement with lug member 150. Second end 144 bof elongated portion 144 defines a recess 147 (FIG. 9) configured toreceive a first end 155 a of a biasing member 155. As shown, biasingmember 155 includes a compression spring; however, any suitable biasingmember may be employed. Second end 144 b of elongated portion 144further includes a pair of ridges 148 configured for operable engagementwith lug member 150.

With reference to FIGS. 3, 7 and 8, lug member 150 includes anengagement portion 152 configured for operable engagement by a user. Asshown, engagement portion 152 includes a grip defining a pair ofrecesses 152 a each configured to be engaged by one or more fingersand/or a thumb of a user. Although shown being configured for operableengagement by two or more fingers and/or a thumb of a user, it isenvisioned that engagement portion 152 of lug member 150 may include anyconfiguration suitable for selective engagement by a user.

With continued reference to FIGS. 3 and 5, lug member 150 defines arecess 151 configured to receive a portion of the articulation handle140, such as second end 144 b of the elongated portion 144 of thearticulation handle 140. As shown, lug member 150 includes a pair ofchannels 153 configured to be slidingly received about ridges 148 onsecond end 144 b of elongated portion 144. Lug member 150 includes aspring engagement tab 154 extending into recess 151 for engaging asecond end 155 b of biasing member 155. Lug member 150 further includesa locking tab 156 extending opposite from engagement portion 152.Locking tab 156 is configured for selective engagement within any ofnotches 135 formed in locking member 130.

With reference now to FIGS. 3 and 4, channel yoke 160 is a substantiallyL-shaped bracket having a horizontal portion 162 and a vertical portion164. Extending from vertical member 164 is a flange 166. Flange 166 isconfigured to engage an articulation linkage 50, which, as discussedabove, is operably connect to an articulable tool assembly (not shown).Horizontal member 162 defines a slot 163 configured to receive adistally extending portion 165 b of cam pin 165.

The assembly of articulation mechanism 100 will now be described withreference to FIGS. 3-6, Prior to attaching upper and lower housinghalves 104, 106 to elongated body 30 of surgical device 10, channel yoke160 is positioned such that flange 166 formed on vertical member 164 ofchannel yoke 160 engages an articulation link 50 extending from withinelongated body 30. As discussed above, longitudinal translation ofarticulation link 50 causes articulation of an articulable toolassembly. Upper and lower housing halves 104, 106 are then fit togetherabout the proximal end of elongated body 30 and the distal end of handleassembly 20. Upper and lower housing halves 104, 106 may be joined witha snap fit connection, mechanical fasteners, bonding, adhesive or anyother suitable method.

With reference still to FIGS. 3-6, cam pin 165 is next secured to baseportion 112 of main shaft 110. Proximal portion 165 a of cam pin 165 isreceived through opening 112 b in base portion 112. In one embodiment,once portion 165 a of cam pin 165 is received through opening 113 b,proximal portion 165 a is peened to secure cam pin 165 to main shaft110. Alternatively, mechanical fasteners or other suitable methods mayused to secure cam pin 165 to main shaft 110. In yet another embodiment,the positioning of articulation mechanism 100 165 relative to main shaft110 maintains cam pin without any additional means. Once cam pin 165 issecured within opening 112 b of in base portion 112, main shaft 110 ispositioned within opening 105 of upper housing half 104 such that distalportion 165 b of cam pin 165 is received within slot 163 formed inhorizontal member 162 of channel yoke 160.

With continued reference to FIGS. 3-6, retainer 120 is next placed overand about shaft portion 114 of main shaft 110 and positioned such thattabs 124 extending radially outward therefrom are received within theslots formed about opening 105 of upper housing half 104. Locking member130 is then received about shaft portion 114. Feet 134 of locking member130 properly align locking member 130 with articulation housing 102.Alternatively, locking member 130 may be secured to upper housing half104 with mechanical fasteners, adhesive, welding or other suitablemethods.

Still referring to FIGS. 3-6, articulation handle 140 is next placed onend 114 a of shaft 114 such that flange portion 146 of articulationhandle 140 is received within semi-circular cut-out 133 of lockingmember 130. Locking pin 145 is then inserted through opening 117 formedin shaft portion 114 of main shaft 110 to secure articulation handle 140to main shaft 110. Locking pin 155 may be secured within opening 117 byfriction fit, adhesive or other suitable method.

With particular reference now to FIGS. 3 and 5, lug member 150 is nextoperably received on second end 144 b of elongated portion 144 ofarticulation handle 140. Lug member 150 is positioned such that ridges148 formed on second end 144 b of elongated portion 144 are receivedwithin channels 153 formed in lug member 150. The lug member is biasedin a direction toward the locking member. Biasing member 155, i.e., acompression spring, is received within recess 147 formed in second end144 b of elongated portion 144 with first end 155 a of biasing member155 engaging second end 144 b of elongated portion 144 and second end155 b of biasing member 155 engaging spring engagement tab 154. In thismanner, lug member 150 is biased inwardly within recess 147 of secondend 144 b and is configured to slide outward relative to second end 144b when a user engages engagement portion 152 thereof.

The use of articulation mechanism 100 will now be described withreference to FIGS. 1 and 9-11. Referring initially to FIGS. 1 and 9,articulation mechanism 100 is shown in an initial position. Whenarticulation mechanism 100 is in the initial position, elongated body 30and an articulable tool assembly (not shown) of surgical device 10 arein a non-articulated or straight configuration. In this configuration,locking tab 156 of lug member 150 is selectively received within centralnotch 135 a of locking member 130.

Articulation mechanism 100 may be configured to interact with one ormore computer and/or electronic components of an operating room system,or such components can be provided in the surgical device. This includesbut is not limited to a sensor mechanism (not shown) of surgical device10. In this manner, surgical device 10 includes a structure extendingthrough elongated shaft 30 which includes a tubular or other shapedmember (not shown) that is displaced upon the engagement with the distalend of the elongated body 30 by a replaceable loading unit that has anarticulatable tool assembly (not shown). Loading units with toolassemblies that do not articulate do not displace the tubular member. Asensor cap (not shown) is arranged with the tubular member so as to bedisplaced. The sensor cap has a portion, such as a protrusion (notshown) that is received in slot 113 a of main shaft 110 to preventmovement of main shaft 110 unless and until the sensor cap is displaced.In this way, articulation mechanism 100 may not be moved unless anarticulable tool assembly is engaged with elongated body 30 of surgicaldevice 10. Slot 113 a is utilized to lock articulation mechanism 100when a tool assembly is not loaded, to unlock articulation mechanism 100when an articulable tool assembly is loaded, and to lock articulationmechanism 100 when a non-articulable tool assembly is loaded. For a moredetailed discussion of the structure and function of the sensormechanism, please refer to previously noted U.S. Pat. No. 5,865,361 toMilliman et al.

Turning now to FIG. 10, engagement of recesses 152 a of engagementportion 152 of lug member 150 by a user and subsequent retraction of lugmember 150 relative to second end 144 b of elongate portion 144, in thedirection of arrow “A”, causes retraction of locking tab 156 of lugmember 150 from within central notch 135 a of locking member 130. Inthis second or unlocked position, articulation handle 140 is free torotate relative to locking member 130. As shown in FIG. 10,counter-clockwise rotation of articulation handle 140 relative tolocking member 130, in the direction of arrow “B”, results inadvancement of yoke 160, and attached articulation linkage 50, in thedirection of arrow “C”. As discussed above, articulation handle 140 issecurely attached to shaft portion 114 of main shaft 110 such thatrotation of articulation handle 140 turns main shaft 110. Base portion112 of main shaft 110 is connected to yoke 160 by cam member 165 suchthat the rotation of main shaft 110 in a first direction causesadvancement of articulation linkage 50 while rotation of main shaft 110in a second direction causes retraction of articulation linkage 50.Advancement and retraction of articulation linkage 50 results inarticulation of a tool assembly in respective first and seconddirections. The amount of rotation of articulation handle 140 is limitedby the engagement of flange portion 146 of articulation handle 140 withfirst and second end walls 133 a, 133 b (FIGS. 7 and 8) of semi-circularcut-out 133 of locking member 130.

With reference to FIG. 11, release of lug member 150 by the clinicianpermits the return of lug member 150 to an initial, non-retractedposition. Lug member 150 is biased to the initial position bycompression spring 155. The return of lug member 150 to the initialposition results in locking tab 156 being received within notch 135,thereby locking articulation handle 140 relative to locking member 130.In this manner, an articulable tool assembly (not shown) mounted on thedistal end of elongate body 30 (FIG. 1) is locked in an articulatedposition. The tool assembly may be further articulated or returned tothe initial, non-articulated position by retracting lug member 150relative to second end 144 b of elongated portion 144 and rotatingarticulation handle 140 relative to locking member 130.

It will be understood that various modifications may be made to theembodiment disclosed herein. For example, with reference to FIG. 12,articulation mechanism 100 may further include a locking mechanism 170for selectively locking lug member 150 relative to elongated portion 144of articulation handle 140. As shown, locking mechanism 170 includes aside mounted button 172 extending through second end 144 b of elongatedportion 144. Button 172 is configured to selectively engage lug member150 to prevent unlocking of articulation handle 140 relative to lockingmember 130. Alternatively, articulation mechanism 100 may include alocking mechanism (not shown) that requires advancing lug member 150relative to elongated portion 144 of articulation handle 140 prior tobeing able to retract lug member 150 relative thereto. Therefore, theabove description should not be construed as limiting, but merely asexemplifications of particular embodiments. Those skilled in the artwill envision other modifications within the scope and spirit of theclaims appended hereto.

1. A surgical device comprising: a handle assembly; an elongated bodyextending from the handle assembly; and an articulation mechanismoperably connected to the handle assembly and configured to selectivelyarticulate and lock an articulatable tool assembly in one or morepositions, the articulation mechanism including: a main shaft membermounted for rotation and connected to an articulation linkage; a lockingmember configured to be received about the main shaft member androtationally fixed relative to the elongated body, the locking memberdefining a plurality of notches; an articulation handle fixedly securedto the main shaft member and configured for rotation relative to thelocking member; and a lug member mounted on the articulation handle, atleast a portion of the lug member being mounted for being selectivelyreceived within a notch of the plurality of notches formed in thelocking member.
 2. The surgical device of claim 1, further including anarticulatable tool assembly mounted on a distal end of the elongatedbody.
 3. The surgical device of claim 1, wherein the plurality ofnotches are evenly spaced.
 4. The surgical device of claim 1, where theplurality of notches includes a central notch for reception of the lugmember when the surgical device is in a non-articulated position.
 5. Thesurgical device of claim 1, wherein the articulation handle includes aflange configured to be received within a cutout in the locking memberto limit rotation of the articulation handle.
 6. The surgical device ofclaim 1, further including a yoke attached to the main shaft member andthe articulation linkage.
 7. The surgical device of claim 1, furtherincluding a locking mechanism for selectively locking the lug memberrelative to the articulation handle,
 8. The surgical device of claim 2,wherein the tool assembly includes an anvil and a staple cartridgeassembly.
 9. The surgical device of claim 1, further comprising aretainer rotationally fixed with respect to the handle assembly.
 10. Thesurgical device of claim 9, wherein the retainer has an opening forreceiving the main shaft member.
 11. The surgical device of claim 1,wherein the lug member defines a recess configured to receive a portionof the articulation handle.
 12. The surgical device of claim 11, whereinthe lug member is biased in a direction toward the locking member. 13.The surgical device of claim 1, further comprising a sensor cap having aportion thereof receivable in a slot of the main shaft.
 14. The surgicaldevice of claim 13, further comprising a loading unit having thearticulatable tool assembly, the loading unit being configured todisplace the sensor caps so that the portion of the sensor cap movesaway from the main shaft.